Insulated Shipping System
An insulating shipping system may include six outer walls configured into a six-sided container; an insulating layer positioned within the outer walls and formed by a plurality of insulating members; and a thermal mass layer positioned within the insulating members and made from a plurality of thermal mass members. The thermal mass members may contain a thermal energy absorbing material. The container also may have a thermal buffer layer configured to fit within the thermal mass layer. All together, these layers form a passive, thermally stabile cargo cavity for transporting temperature-sensitive cargo.
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The present application claims the benefit of U.S. Provisional Application No. 62/283,598, filed Sep. 8, 2015, entitled “Insulated Pallet Shipper Constructed From Fiber Board And Cellulose, Denim and lor [sic.] Jute Fiber”, which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION 1. Technical FieldThe present invention generally relates to insulated shipping systems.
2. Related ArtSystems exist for shipping temperature sensitive cargo. Some of these systems use foam, such as expanded polystyrene (EPS) or extruded polystyrene foam (XPS). While plastic foams such as these can provide insulating properties, they are usually not recyclable or biodegradable. Additionally, foam products tend to be bulky and take up a significant amount of space, making them difficult and expensive to ship.
While some recyclable or partially-recyclable systems for transporting temperature sensitive cargo exist, they are sometimes not actually recycled in practice. These systems can require the end user to separate the constituent materials with significant effort. These unrecycled systems can end up in landfills, leading to negative environmental effects.
Existing passive insulating systems can maintain the temperature of the package for only a limited time, sometimes less than a day. Systems which maintain temperature-sensitive cargo for longer periods of time may require active cooling from the transporting vehicle. Such systems for transporting temperature-sensitive cargo can be dependent on energy-intensive cooling or heating systems that are inefficient and potentially damaging to the environment. Additionally, such systems can be subject to failure, thereby potentially exposing temperature-sensitive cargo to improper temperatures.
Prior art methods can be inefficient, costly, and negatively impact the environment. Passively insulated systems may be unable to maintain temperature sensitive cargo at a predetermined temperature for extended periods of time, and actively heated and cooled systems can be expensive and subject to malfunction. Such systems can have negative environmental impacts.
SUMMARYIn one aspect, an insulated shipping system may comprise six walls, an insulating layer fitting within said six walls, and a thermal mass layer fitting within said insulating layer, wherein said thermal mass layer substantially surrounds a cargo space and said insulating layer substantially surrounds said thermal mass layer.
In another aspect, a system may include a thermal buffer layer fitting within said thermal mass layer, wherein said thermal buffer layer may substantially surround said cargo space.
In another aspect, a system may use thermal gel as the thermal energy absorbing material.
In another aspect, a system may include exterior members made from corrugated fiberboard.
In another aspect, a system may include thermally insulating material that is recyclable.
As shown in
Cargo cavity 50 may have dimensions ranging from about 30 inches to about 40 inches long, about 20 inches to about 30 inches wide, and about 15 inches to about 35 inches high. Preferably, in a 48″ tall embodiment of system 10, cargo cavity 50 may be about 32¼ inches long, about 23 11/16 inches wide, and about 33 inches tall.
As seen in
System 10 may have outer walls, an insulating layer, and a thermal mass layer. These fit together to form a six sided insulated container as shown in
The length of system 10 may range from about 40 inches to about 56 inches. Preferably the length is between about 44 inches and about 52 inches and more preferably between about 46 inches and about 50 inches. The width of system 10 may range from about 32 inches to about 48 inches. Preferably the width is between about 36 inches and about 44 inches and more preferably between about 38 inches and about 42 inches. The height of system 10 may range from about 20 inches to about 64 inches. Preferably, in one size, the height is between about 40 inches and about 56 inches and more preferably between about 46 inches and about 50 inches. One possible discrete size of system 10 (“the 24″ tall embodiment”) is about 48 inches long, about 40 inches wide, and about 24 inches tall. Another possible size of system 10 (“the 48″ tall embodiment”) is about 48 inches long, about 40 inches wide, and about 48 inches tall. Another possible size of system 10 (“the 60″ tall embodiment”) is about 48 inches long, about 40 inches wide, and about 60 inches tall.
The combined interaction of the various layers maintains temperature-sensitive cargo within a predetermined range of temperatures. Although more or fewer layers may be used, the layers in one possible embodiment, when described from the outermost to innermost layers, are: the outer wall, insulating layer, thermal mass layer, and thermal buffer layer. The combined thickness of all four layers combined may range from about 2 to about 12 inches and more preferably range from about 6 to about 9 inches. The combined thickness of the wall and three layers is most preferably about 7½ inches thick. System 10 is scalable to different sizes depending on the size of cargo cavity 50 required by the end user. The thickness of each layer, and thus the total thickness, may vary based on the desired shape and size of cargo cavity 50, the nature of the cargo, the temperature and humidity conditions of the external environment, and the time for which system 10 must maintain a stable temperature of the cargo.
Some embodiments may include a trapdoor (not shown) to access cargo cavity 50 without requiring disassembly of system 10. Such a trapdoor, however, may reduce the thermal performance of system 10, e.g., by allowing additional air exchange between the environment and cargo cavity 50.
Various components of system 10 are designed to substantially abut next to adjacent components. This design may improve the structural stability and rigidity of system 10 and may prevent undesired air circulation which in turn may impact heat transfer.
2. Thermal Performance of the Insulated Shipping Container2.1 Thermal Mass Layer
As shown in
The amount and temperature of thermal gel used in each application may vary based on the needs of the temperature-sensitive cargo and the size of system 10. In one possible embodiment, system 10 may carry about eighteen payload boxes, such as the boxes disclosed in U.S. Pat. No. 8,763,886 to Hall. The '886 payload boxes may also contain additional frozen thermal gel in about two gel packs holding about 24 ounces of gel each, or about 3 pounds in each payload box and about 54 pounds in all payload boxes. Each '886 payload box may contain a quantity of about five vials each holding about 10 ml. of temperature-sensitive cargo. In total, the about eighteen payload boxes may contain about ninety vials, or about 900 ml of temperature-sensitive cargo. Thermal gel packs used in system 10 may each contain about 32 ounces of thermal gel. In total, system 10 may contain about 122 frozen thermal gel packs, or about 224 pounds total of thermal gel. In combination with the payload boxes, system 10 can hold in total about 298 lbs of frozen thermal gel. The thermal performance of this one embodiment is shown in the graph in
Thermal gel may be packaged in rigid thermal gel bricks, such as the PROPAK™ FRIGIDBRICK™ gel brick, or the like. In total, one embodiment of system 10 may contain up to about ninety-five thermal gel bricks that each contain 30 ounces of thermal gel. This leads to a total mass of thermal gel bricks of about 180 pounds, and total mass of gel in system 10, including gel in the payload boxes, may be about 254 pounds.
The amount of total thermal gel in system 10 may range from about 0 pounds to about 600 pounds and more preferably between about 150 to about 450 pounds and most preferably between about 200 and about 300 pounds. Although 24 ounce and 30 ounce gel packs or bricks are described above, any mass of gel pack or gel brick 480 may be used in different embodiments of system 10.
Throughout this application, it all be understood that references to gel amounts refer to predetermined capacity, and that not all of the capacity will need to be used in every situation, but, instead, a predetermined amount of gel may be placed in system 10 according to expected temperatures, shipping times, and other parameters known to those of ordinary skill.
The thermal mass layer may alternatively include other thermal energy absorbing materials, such as frozen water, frozen carbon dioxide (often called “dry ice”), or any other material with desirable thermal properties, such as high specific heat capacity, high latent heat of fusion, and/or high latent heat of vaporization.
2.2 Outer Layer, Thermal Insulating Layer, and Thermal Buffer Layer
Other layers of system 10 enhance thermal mass layer's ability to maintain a stable temperature of the temperature-sensitive cargo. Outer layer made from side exterior members 202b and top/bottom exterior members 202a may serve as insulation and may provide structural support for system 10. Exterior members 202a and 202b may slow the rate at which heat energy is transferred into system 10 from the external environment. Moving towards the center of system 10, the next layer, the insulating layer, is formed from insulating members 302a, 302b, and 302c. Also, insulating members, such as top/bottom insulating member 302a may contain thermally insulating material 350a which serve to possibly slow the rate of heat transfer deeper inside system 10.
Again moving towards the center of system 10, the next layer, the thermal mass layer, may be used to absorb at least some of the remaining heat energy that penetrates through the outer layer and insulating layer. By providing thermal mass, the thermal energy absorbing material inside thermal mass members may prevent excessive heat energy from the external environment from reaching the temperature sensitive cargo in cargo cavity 50 for over 100 hours. The thermal buffer layer, made from thermal buffer panels 502a, 502b, and 502c, may provide a thermal buffer between the thermal mass layer and the temperature-sensitive cargo, so the cargo may not cool too much below a desired threshold temperature.
2.3 Testing Data
The thermal characteristics of a possible embodiment of system 10 is shown in
As illustrated in
Alternatively, system 10 may be used without thermal energy absorbing material and used simply for its insulating properties if only a limited duration of temperature stabilization is needed.
3. Materials and ConstructionWhen referring to illustrations of the blanks, the usual drawing conventions are applied. That is, unless otherwise indicated, broken lines indicate lines of weakness, such as fold or score lines, which facilitate rotating or folding portions of a blank; and interior solid lines indicate through-cuts. Also, when score lines and/or fold lines are referred to herein, in alternative embodiments, a score line may be replaced with a fold line or another line of weakness, and/or a fold line may be replaced with a score line or another line of weakness.
Additionally, when flanges and/or tabs are referred to herein, in alternative embodiments, a flange may be replaced with a tab or another projection, and/or a tab may be replaced with a flange or another projection. Moreover, when notches and/or slots are referred to herein, in alternative embodiments, a notch may be replaced with a slot or another cut, and/or a slot may be replaced with a notch or another cut.
Generally, a blank may be a single panel or it may be folded into two, three, four, or more panels. Similarly, when panels are shown as individual members, two or more such panels alternatively may be formed by folding a blank into the desired number of shapes and panels.
In preferred embodiments, blanks are fabricated from corrugated fiberboard material, although other materials having similar suitable performance characteristics may be employed if desired. For example, other materials may include paperboard, cardboard, non-corrugated fiberboard, polymers, metal foil, and/or biodegradable material such as biodegradable film, paper, or fiber. When made from corrugated fiberboard, blanks may be made from single or double wall corrugated fiberboard. Single wall fiberboard comprises one layer of fluted paper that is sandwiched between two smooth fiberboard paper layers. These three layers form one single wall fiberboard. Double wall fiberboard comprises three layers of smooth fiberboard paper with one layer of fluted paper sandwiched in between each layer of smooth fiberboard paper, for five total layers. The single wall fiberboard may have a thickness between about 1/16 inch and about ½ inch, preferably between about ⅛ inch and about ⅜ inch, more preferably about ¼ inch. The double wall fiberboard may have a thickness between about ⅛ inch and about 1 inch, preferably between about ¼ inch and about ⅞ inch, more preferably about ⅜ inch.
Certain blanks and/or components may be coated on one or more sides in a waterproof recyclable coating to prevent deterioration and/or weakening of fiberboard products when subjected to damp environments or from other water sources. Coating may include MICHELMAN® MICHEM® Coat 40 Plus or the like, which is applied to fiberboard products to provide water and oil resistance. MICHEM® Coat 40 Plus is a water-based coating that, when dry, resists water, oil, and grease from penetrating corrugated fiberboard.
Moreover, in some embodiments, blanks may be fabricated, erected, and/or articulated using adhering or adhesive materials, such as tape, glue, and/or a sealant. When adhesive materials are used, one or more layers may be fabricated, erected and/or articulated without adhering or adhesive materials. For example, tabs, flanges, slots, and/or notches maybe be used to fabricate, erect, and/or articulate a blank. System 10 may also be assembled using staples, nails, screws, clips, rivets, and/or other fasteners.
Preferably, system 10 is assembled using assembly tabs. These tabs reduce adhesive costs and improper gluing procedure during assembly. Additionally, they allow system 10 to be assembled and disassembled repeatedly without damage, improving its recyclability.
Preferably, the various components of system 10 fit together snugly by substantially abutting next to the adjacent component with no perceivable air gap. This promotes thermal efficiency and ensures a strong, physically stable structure.
Preferably, system 10 may be shrink wrapped either on or off of a shipping pallet. This shrink wrap provides additional stability and air-trapping properties, although it is not required for system 10 to function properly. Additionally, the bottom cap and/or bottom exterior member 202 may be attached to a pallet with staples and/or other fasteners to further secure system 10 to a shipping pallet.
4. Outer WallsIn addition to the thermal energy absorbing material, system 10 includes other layers which may shield the temperature-sensitive cargo from temperature variations from the outside environment. As seen in
4.1 Overall Dimensions Based on Exterior Members
The length of each side of system 10, as formed by the long panel of side exterior members 202b may range from about 40 to about 56 inches long. The width of system 10, as formed by the short panel of side exterior member 202b, may range from about 32 inches to about 48 inches. The height of system 10, as formed by side exterior members 202b, may range from about 24 inches to about 60 inches. One possible discrete size of system 10 is about 48 inches long, about 40 inches wide, and about 24 inches tall. Another possible size of system 10 is about 48 inches long, about 40 inches wide, and about 48 inches tall. Another possible size of system 10 is about 48 inches long, about 40 inches wide, and about 60 inches tall.
4.2 Exterior Member Dimensions
Flap 204 may be about 0 to about 10 inches wide, with the ideal length being about 6 inches wide. The length of top/bottom exterior members 202 may be from about 40 inches to 56 inches. Preferably, the top/bottom exterior members 202a are about 47 7/16 inches long. The width of top/bottom exterior members 202a range from about 32 inches to 48 inches. Preferably, top/bottom exterior members 202a are about 39⅜ inches wide. Top/bottom exterior members 202a serve as the remaining two sides of system 10, such that all six sides formed by two side exterior members 202b and two top/bottom exterior members 202a form a substantially rectangular cuboid box. As seen in
Moving inward to the first internal layer of system 10, after the side external members 202b and top/bottom insulating members 202a, is insulating layer comprised of six insulating members 302a, 302b, and 302c, as shown in
A long side insulating member 302b may removably attach to each long side panel of both side exterior members 202b using four tabs 206. Tabs 206 are cut out of the long panel side of each side exterior member 202b and interface with slots 314b cut into long side insulating member 302b.
A short side insulating member 302c may removably attach to each short side panel of both side exterior members 202b using two tabs 206. Tabs 206 are cut out of the short panel side of each side exterior member 202b and interface with slots 314c cut into the short side insulating member 302c.
A top/bottom insulating member 302a is removably attached to each top/bottom exterior members 202a using four tabs 206. Tabs 206 are cut out of the side of each top/bottom exterior member 202a and interface with slots 314a cut into top/bottom insulating member 302a.
Two of each insulating members 302a, 302b, and 302c form the six sides of the thermal insulating layer.
5.1 Insulating Member Dimensions
As shown in
Of the three sizes of insulating member that are used in the 48″ tall embodiment of system 10, the long side size insulating member 302b may be about 40 11/16 inches tall, about 46⅝ inches long, and about 3 5/16 inches thick. The short side size insulating member 302c may be about 40 11/16 inches tall, about 31⅝ inches long, and about 3 5/16 inches thick. The top/bottom size insulating member 302a may be about 46 9/16 inches long, about 38 5/16 inches wide and about 3 5/16 inches thick.
Each insulating member 302a, 302b, and 302c is structurally similar and contain and generally the same elements, albeit labeled with each member's corresponding letter. Only one size insulating member, insulating member 302a, is shown in
Thermally insulating material 350a fills at least some of the space resulting from folding blank into insulating member 302a. Preferably, thermally insulating material 350a is formed from a recyclable material with good thermal insulating properties, such as cellulose, hemp, jute, cotton, or a combination thereof, although any material with good thermal insulating properties can be used.
6. Thermal Mass LayerMoving inward from the insulating layer formed by insulating panels, system 10 includes a thermal mass layer formed from six thermal mass members 402a, 402b, 402c and 402d, as shown in
6.1 Thermal Mass Member Dimensions
In a 48″ tall embodiment of system 10, the long side thermal mass member 402b may be about 37 3/16 inches wide by about 35⅛ inches tall by about 2¾ inches thick. The short side thermal mass member 402c may be about 28 15/16 inches wide and about 35⅛ inches tall and about 2¾ inches thick. The top/bottom thermal mass member 402a may be about 31⅝ inches wide and about 39⅞ inches long and about 2¾ inches thick. The internal thermal mass member 402d may be about 23 11/16 inches wide and about 32 ¼ inches long and about 2¾ inches thick.
The thermal mass layer may be formed with six thermal mass members. Two long side thermal mass members 402b may be used. Each top/bottom thermal mass member's 402a exterior face 404a is located adjacent to the top/bottom insulating member 302a. This forms two of the sides of system 10, the top and bottom. Similarly, each long side thermal mass member 402b is located adjacent to each long side insulating member 302b. Each short side thermal mass member 402c is located adjacent to each short side insulating member 302c. These form the remaining four sides of system 10. These combine with the two sides formed by the top/bottom thermal mass members 402a to form the six sides of insulating layer of system 10.
System 10 may include one or more internal thermal mass members 402d. Such member can be used if additional thermal mass is needed to keep the cargo at a specific temperature range.
6.2 Vent Holes
Thermal mass members 402a, 402b, 402c, and 402d may contain vent holes 450. One embodiment may contain twelve equally spaced vent holes on interior facing wall 408a of each thermal mass member. Vent holes 450 align with vent holes 460 located on thermal mass support 452a. The function of vent holes 450 and 460 is explained below.
7. Thermal Mass SleevesSystem 10 may include thermal mass sleeves. As shown in
7.1 Thermal Mass Sleeve Dimensions
Three sizes of thermal mass sleeves may be used each embodiment of system 10, although only one is shown because each size has sufficiently the same structure. One size fits in the long and short side thermal mass members 402b and 402c, the top/bottom thermal mass sleeves 452a fit in the top/bottom thermal mass members 402a, and a third size fits in the internal thermal mass member 402d. About four top/bottom thermal mass sleeves 452a fit in each top/bottom thermal insulating member 402a, for about eight total. About five side thermal mass sleeves fit in each long side thermal mass member 402b, for about ten total. About four side thermal mass sleeves fit in each short side thermal mass member 402c, for about eight total. Finally, about three internal thermal mass sleeves fit in the internal thermal mass member 402d.
In a 48″ tall embodiment, the side thermal mass sleeve may be about 34 ½ inches long, about 7 inches wide, and about 2 7/16 inches thick. The top/bottom thermal mass sleeve 452a may be about 39¼ inches long, about 7⅝ inches wide, and about 2 7/16 inches thick. Internal thermal mass sleeve may be about 31⅝ inches long, about 7¾ inches wide, and about 2 7/16 inches thick.
7.2 Vent Holes
Thermal mass supports 452a may contain vent holes 460a both sides. There may be three vent holes 460a on each wall of thermal mass sleeve 452a. Holes 460a may be placed on both sides of the thermal mass sleeve 452a, to allow the sleeve to be inserted in either direction without impacting thermal performance. Vent holes 460a align with vent holes 450a of each thermal mass member 402a when each thermal mass sleeve 452a is inserted into thermal mass member 402a. The combination of vent holes 450a and 460a provide a route of increased heat transfer between thermal energy absorbing material and the surrounding layers. There may be twelve total vent holes on each thermal mass member 452a.
8. Thermal Buffer LayerAs seen in
8.1 Thermal Buffer Panel Dimensions
Returning to
In a 48″ tall embodiment, long side thermal buffer panel 502b may be about 33 inches tall by about 33⅜ inches wide. Short side thermal buffer panel 502c may be about 33 inches tall by about 25 inches wide. Top/bottom thermal buffer panel 502a may be about 34¼ inches long by about 26 inches wide.
9. End CapsAs shown in
9.1 End Cap Dimensions
The dimensions of end cap may range from about 40 inches to about 56 inches long and from about 32 inches to about 48 inches wide. Long side flaps 252 may range from about 1 inch to 6 inches wide and short side flaps 254 may range from about 2 inches to about 10 inches wide. In all embodiments, end cap may be about 48 inches long and 40 inches wide and long side flaps may be about 4 7/16 inches wide and short side flaps may be about 7 inches wide.
10. Complete AssemblyFirst, as shown in
Moving on to
Next is the assembly of the thermal mass layer, shown in
Moving on to
As seen in
Turning to
Finally, in
It will be understood by those of ordinary skill that the components of system 10 may be shipped from the manufacturer to the user location in mostly knocked-down and flat form, i.e., ready to assemble. Some sub-assemblies may be pre-assembled, for example, those that are glued, such as insulation members and thermal mass sleeves. It may be desirable and attainable to provide the user with a system 10 that can be assembled largely or entirely without staples, fasteners, glue, tape, or the like. In this way, assembly is relatively easy and almost foolproof. Instructions such as the sequence of
10.1 Alternative Loading Method
System 10 may also be configured to allow the short side of exterior member 202b to open, which allows loading from the side instead of the top of system 10. Such a configuration may be achieved by removing tabs 256 from one side of both the top and bottom end caps 250 and swinging the short side of external member 202b open along fold line 220. Next the short side thermal insulting member 402c may be removed, along with the short side thermal buffer panel 502c, allowing access to cargo cavity 50.
It will be understood by those of ordinary skill that thermally biased, e.g., refrigerated or frozen, gel packs or bricks may be loaded into sleeves, and sleeves into thermal mass members, on site by the user. Similarly, it will be understood that system 10 may be loaded or unloaded as needed, e.g., over a period of time or in a series of locations.
While particular elements, embodiments, and applications of the present invention have been shown and described, it is understood that the invention is not limited thereto because modifications may be made by those skilled in the art, particularly in light of the foregoing teaching. It is therefore contemplated by the appended claims to cover such modifications and incorporate those features which come within the spirit and scope of the invention.
11. Additional Detailed DescriptionAs seen in
System 10 may also include a thermal buffer layer made from thermal buffer panels 502a, 502b, and 502c fitting within said thermal mass layer where the thermal buffer layer substantially surrounds said cargo cavity 50.
Exterior members 202a and 202b may be made from corrugated fiberboard.
Exterior members 202a and 202b may be made from double wall corrugated fiberboard.
System 10 may also include two end caps 250 forming a base and a top.
The outer walls of system 10 are made of four sidewalls made from two side exterior members 202b and a top and bottom wall both made from one exterior member 202a;
The insulating layer may include two long side insulating members 302b, two short side insulating members 302c, and two top/bottom insulating members 302a.
The thermal mass layer may include two long side thermal mass members 402b, two short side thermal mass members 402c, and two top/bottom thermal mass members 402a.
The thermal mass members 402a, 402b, and 402c may contain a plurality of thermal gel bricks 480 and may include vent holes 450.
The thermal buffer may include two long side thermal buffer panel 502b, two short side thermal buffer panel 502c, and two top/bottom thermal buffer panel 502a.
Each top/bottom exterior members 202a may interlock with each top/bottom thermal insulating member using four tabs 206. Each side exterior member 202b may interlock with one long side thermal insulating panel 302b and one short side thermal insulting panel 302c using six tabs 206.
System 10 may be about 48 inches long, about 48 inches high, and about 40 inches wide.
Each one of thermal insulating members 302a, 302b, and 302c may have a thickness of between about 2 and about 4 inches;
Each one of thermal mass members 402a, 402b, 402c, and 402d may have a thickness of between about 1½ and about 3½ inches; and
Each thermal buffer panels may have a thickness of between about ⅛ and about 1½ inches.
The overall thickness of each side of system 10, including one exterior member 202a or 202b; one thermal insulting member 302a, 302b, or 302c; one of thermal mass member 402a, 402b, or 402c; and one of thermal buffer panel 502a, 502b, or 502c; may be between about 5 and about 8 inches.
Thermal buffer panels 502a, 502b, and 502c may have a honeycomb construction.
The thermal energy absorbing material may be thermally biased gel.
The thermal energy absorbing material may be frozen carbon dioxide.
Thermal mass members include thermal mass sleeves which may be configured to fit inside said thermal mass members.
Thermal mass members 402a, 402b, 402c, and 402d may include vents 450 leading toward said cargo cavity 50.
Thermal insulating members 302a, 302b, and 302c may be made from corrugated fiberboard.
Thermal mass members 402a, 402b, 402c, and 402d may be made from corrugated fiberboard.
Thermal buffer panels 502a, 502b, and 502c may be made from corrugated fiberboard.
Thermally insulating material 350a may be recyclable.
The mass capacity of thermally biased gel such as in gel bricks 480 in sleeves in system 10 may be between about 150 and about 200 pounds.
Claims
1. An insulating shipping system comprising:
- six walls;
- an insulating layer fitting within said six walls; and
- a thermal mass layer fitting within said insulating layer;
- wherein said thermal mass layer substantially surrounds a cargo cavity and said insulating layer substantially surrounds said thermal mass layer.
2. The insulating shipping system according to claim 1, further comprising
- a thermal buffer layer fitting within said thermal mass layer;
- wherein said thermal buffer layer substantially surrounds said cargo cavity.
3. The insulating shipping system according to claim 1, wherein
- said outer walls are made from corrugated fiberboard.
4. The insulating shipping system according to claim 1, wherein
- said outer walls are made from double wall corrugated fiberboard.
5. (canceled)
6. (canceled)
7. (canceled)
8. The insulating shipping system according to claim 2, wherein
- said thermal buffer layer includes a plurality of buffer panels, each said buffer panel has a honeycomb construction.
9. The insulating shipping system according to claim 1, wherein
- said thermal mass layer is adapted to hold thermal energy absorbing material therein,
- said thermal energy absorbing material is thermally biased gel.
10. The insulating shipping system according to claim 1, wherein
- said thermal mass layer is adapted to hold thermal energy absorbing material therein,
- said thermal energy absorbing material is frozen carbon dioxide.
11. The insulating shipping system according to claim 1, wherein
- said thermal mass layer includes a plurality of thermal mass members, said thermal mass members include internal thermal mass supports which are configured to fit inside said thermal mass members;
- such that said thermal mass supports reduce the relative movement of thermal energy absorbing material retained therein.
12. The insulating shipping system according to claim 1, wherein;
- said thermal mass layer includes vents on an interior side leading into said cargo cavity.
13. The insulating shipping system according to claim 1, wherein
- said insulating layer includes a plurality of insulating members, said insulating members are made from corrugated fiberboard.
14. The insulating shipping system according to claim 11, wherein
- said thermal mass members are made from corrugated fiberboard.
15. The insulating shipping system according to claim 8, wherein
- said thermal buffer panels are made from corrugated fiberboard.
16. The insulating shipping system according to claim 13, wherein
- said insulating members include insulating material that is recyclable.
17. The insulating shipping system according to claim 9, wherein
- the mass capacity of thermally biased gel in sleeves is in the range of 150 to 200 pounds.
Type: Application
Filed: Dec 21, 2017
Publication Date: Aug 2, 2018
Applicant: EKOPAK, Inc. (Coraopolis, PA)
Inventors: Lonny Vogel (North Huntingdon, PA), Christopher Edward Hall (North Huntingdon, PA)
Application Number: 15/851,167